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Abstract:

The subject of the invention is an anode block (13, 13a-13e) made of
carbon for a pre-baked anode (4) for use in a metal electrolysis cell (1)
comprising a higher face (24), a lower face (23), designed to be laid out
opposite a higher face of a cathode (9), and four side faces (21,22,34),
and including at least one first groove (31a-31e) leading onto at least
one of the side faces, in which the first groove has a maximum length
Lmax in a plane parallel to the lower face, and characterized in
that the first groove does not lead onto said lower or higher faces, or
leads onto said lower or higher faces over a length L0 less than
half the maximum length Lmax.

Claims:

1. An anode block made of carbon for a pre-baked anode for use in a metal
electrolysis cell comprising a higher face, a lower face, configured to
be laid out opposite a cathode higher face, and four side faces, and
including at least one first groove leading onto at least one of the side
faces, in which the first groove has a maximum length Lmax in a
plane parallel to the lower face, and characterized in that the first
groove does not lead onto the lower or higher faces, or leads onto said
lower or higher faces over a length L0 less than half the maximum
length Lmax.

2. An anode block according to claim 1, in which the first groove leads
onto two opposite sides faces of the anode block.

3. An anode block according to claim 1, comprising at least one second
groove of maximum length L'max in a plane parallel to the lower face
and leading onto the lower face over a length L'0 substantially
equal to Lmax.

4. An anode block according to claim 1, comprising a plurality of first
grooves.

5. An anode block according to claim 3, comprising two second grooves and
a first groove, in which the first and the second grooves extend in
parallel in the longitudinal direction from the anode block and in which
the first groove is laid out halfway between the two second grooves.

6. An anode block according to claim 1, in which the first groove does
not lead onto said lower or higher faces.

7. An anode block according to claim 1, in which the first groove leads
onto the lower face over a length L0 less than half the maximum
length Lmax.

8. An anode block according to claim 7, in which the length over which
the first groove leads onto the lower face is less than 25% of the
maximum length Lmax.

9. A pre-baked anode comprising at least one anode block according to
claim 1.

10. A cell for the production of aluminum by igneous electrolysis
comprising a plurality of anodes, characterized in that at least one of
the anodes is an anode according to claim 9.

11. A process for the manufacture of aluminum including stages
comprising: providing at least one pre-baked anode comprising at least
one anode block made of carbon for use in a metal electrolysis cell
comprising a higher face, a lower face, configured to be laid out
opposite a cathode higher face, and four side faces, and including at
least one first groove leading onto at least one of the side faces, in
which the first groove has a maximum length Lmax in a plane parallel
to the lower face, and characterized in that the first groove does not
lead onto the lower or hit her faces or leads onto said lower or hi her
faces over a length L0 less than half the maximum length Lmax;
fitting the anode in an aluminum electrolysis cell above a cathode;
sending current into the electrolysis cell through the anode; recovering
the aluminum obtained by electrolysis in the bottom of the electrolysis
cell.

12. A process for the manufacture of an anode block made of carbon for a
pre-baked anode for use in a metal electrolysis cell comprising a higher
face, a lower face, configured to be laid out opposite a cathode higher
face, and four side faces, and including at least one first groove
leading onto at least one of the side faces, in which the first groove
has a maximum length Lmax in a plane parallel to the lower face, and
characterized in that the first groove does not lead onto the lower or
higher faces, or leads onto said lower or higher faces over a length
L0 less than half the maximum length Lmax, the process
comprising: inserting a blade inside a vibrocompactor mold; loading the
vibrocompactor mold is-leaded-with carbonaceous materials that make up
the anode block; vibrocompacting the carbonaceous materials; and removing
the anode block thus formed from the mold.

13. A process according to claim 12, in which the blade is withdrawn from
the mold before removing the anode block.

14. A process according to claim 12, in which the anode block is removed
by slippage in relation to the blade.

15. A process according to claim 12, in which the blade is fixed to the
bottom of the mold.

16. A process according to one of claim 12, in which the blade is fixed
to one lateral face or two opposed lateral faces of the mold before
loading

17. An anode block according to claim 8, in which the length over which
the first groove leads onto the lower face is less than 10% the maximum
length Lmax

Description:

SCOPE OF THE INVENTION

[0001] The invention relates to the production of aluminum by igneous
electrolysis using the Hall-Heroult process, and more particularly the
pre-baked anodes used in aluminum production plants and comprising an
anode block made of carbon, a manufacturing process for such anode blocks
and a device designed for the manufacture of such anode blocks.

BACKGROUND OF RELATED ART

[0002] Metallic aluminum is produced industrially by igneous electrolysis,
namely by electrolysis of alumina in solution in a molten cryolite bath,
known as an electrolysis bath, using the well-known Hall-Heroult process.
The electrolysis bath is contained in cells which comprise a steel
container coated on the inside with refractory and/or insulating
materials, and cathodic elements located at the bottom of the cell. Anode
blocks made of carbonaceous material are partially immersed in the
electrolysis bath. Each tank and the corresponding anodes form what is
often called an electrolysis cell. The electrolysis current, which
circulates in the electrolysis bath, and possibly a layer of liquid
aluminum via the anodes and the cathodic elements, causes the reduction
reactions of alumina and also makes it possible to maintain the
electrolysis bath at a temperature of about 950° C. by Joule
effect.

[0003] French patent application FR 2.806.742 (corresponding to American
patent U.S. Pat. No. 6,409,894) describes installations in an
electrolysis plant designed for the production of aluminum.

[0004] According to the most widespread technology, the electrolysis cells
comprise a plurality of anodes said to be "pre-baked", made of
carbonaceous material. These are consumed during the aluminum
electrolytic reduction reactions.

[0005] Gases, especially carbon dioxide, are generated during the
electrolysis reactions and naturally accumulate in the form of gas
bubbles under the generally substantially flat and horizontal lower
surface of the anode, which influences the overall stability of the cell.

[0006] The accumulation of these gas bubbles causes: [0007] electrical
variations and instabilities, [0008] a high frequency and long duration
of anode effects, [0009] an increased possibility of the opposite
reaction and therefore a loss of productivity because of the short
distance between the layer of aluminum produced and the CO2 bubbles,
[0010] an increased consumption of carbon and the formation of harmful
gases because of the transformation of CO2 as it comes into contact
with the carbon.

[0011] The use of pre-baked anodes with carbonaceous anode blocks
comprising one or more grooves in their lower part is known; these
facilitate the removal of the gas bubbles and prevent them from building
up in order to solve the problems stated above and to reduce energy
consumption, as shown in Light Metals 2005 "Energy saving in Hindalco's
Aluminum Smelter", S. C. Tandon & R. N. Prasad. The grooves make it
possible to decrease the average free path of the gas bubbles under the
anode to get out from the space between the electrodes and thereby to
reduce the size of the bubbles which are formed under the anode.

[0012] The value of the use of grooves has already been studied and
proven, for example in Light metals 2007 p. 305-310 "The impact of slots
on reduction cell individual anode current variation", Geoff Bearne,
Dereck Gadd, Simon Lix, or Light metals 2007 p. 299-304 "Development and
deployment of slotted anode technology at Alcoa", Xiangwen Wang et al.

[0013] It is also known, from the following documents: [0014] WO
2006/137739, to use finer grooves (about 2 to 8 mm) than those commonly
used (about 8 to 20 mm) so as to optimize the useful carbonaceous mass
and the exchange surface; [0015] U.S. Pat. No. 7,179,353, to use an anode
block comprising grooves leading to a single side or side surface of the
anode block, and more particularly towards the center of the electrolysis
cell so as to improve alumina dissolution.

[0016] A well-known limit to the use of these grooves results from the
fact that the depth of the grooves from the lower surface of the anode
blocks is limited in order not to disturb the mechanical and physical
intactness of the carbonaceous anode blocks. However the carbonaceous
anode blocks are gradually consumed during the electrolysis reaction over
a height greater than the depth of the grooves so that the duration of
the grooves of an anode is shorter than the lifespan of the anode.
Consequently, for a certain amount of time during the lifespan of the
anodes the lower part of the anode blocks no longer has any groove. The
problems stated above for anodes without grooves then become noticeable.

[0017] As stated in Light metals 2007 p. 299-304 "Development and
deployment of slotted anode technology at Alcoa", the depth of the
grooves is limited for reasons of intactness mainly in the case of
grooves formed by molding on crude anode blocks so that the beneficial
effects resulting from the presence of the grooves can be observed only
during part of the lifespan of the anodes. The grooves create weaknesses
in the crude anode blocks which then split during transport, storage or
baking.

[0018] In practice it also proves difficult and expensive to reliably
obtain by sawing baked anode blocks anodes with grooves as deep as the
height of the anode block that will be consumed. The mechanical strains
and vibrations exerted by sawing blades cause the carbon blocks to
crumble, craze, and then burst. Anode sawing additionally proves to be an
expensive exercise, particularly on account of the high cost of the
sawing equipment, the large amount of energy required, and the collection
and treatment of the powders produced by sawing.

[0019] The dimensions of the anode blocks for anodes commonly used are of
about 1200 to 1700 mm in length, 500 to 1000 mm in width and 550 to 700
mm in height, with one to three grooves of a depth generally ranging
between 150 and 350 mm.

[0020] For a 600 mm high anode block with a height of consumable carbon of
400 mm and a 250 mm deep groove, the groove produces a beneficial effect
during only 62.5% of the lifespan of the anode.

[0021] A first aim of the invention is to propose another type of anode to
solve the problems of removing the gas building up under the anodes
without compromising the intactness of the anode blocks while they are
being manufactured, stored, transported or used.

[0022] Another aim of the invention is to propose anodes making it
possible to cure the disadvantages stated above, i.e. to propose anodes
producing a beneficial effect for a greater length of time without
compromising the intactness of the anode blocks while they are being
manufactured, stored, transported or used.

DESCRIPTION OF THE INVENTION

[0023] To this end, the subject of the invention is an anode block made of
carbon for a pre-baked anode for use in a metal electrolysis cell
comprising a higher face, a lower face, designed to be laid out opposite
a higher face of a cathode, and four side faces, and including at least
one first groove leading to at least one of the side faces, in which the
first groove has a maximum length Lmax in a plane parallel to the
lower face, and characterized in that the first groove does not lead to
the lower or higher faces, or leads to said lower or higher faces over a
length Lo less than half the maximum length Lmax.

[0024] In other words, the first groove according to the invention forms a
recess in the heart of the material making up the anode block which is
not open onto the lower or higher faces over part of the length of said
groove.

[0025] The higher face of the anode block additionally comprises at least
one fitting recess, and the lower face of the anode block is designed
when in use to be immersed in an electrolysis bath. "Groove" is taken to
mean, as is known from prior art, an extended, substantially vertical
recess of depth ranging between 50 and 500 mm and of width ranging
between 5 and 40 mm.

[0026] Such a first groove has the effect of reducing the turbulence of
the electrolysis bath and the kinetic energy of turbulence for the volume
located below the lower face of the anode block, when it leads onto a
significant length on the lower face, i.e. after a certain amount of wear
of the anode block. The reduction in turbulence is particularly
beneficial in the area below the anode block because it reduces the
re-oxidation of metal dissolved in the electrolysis bath.

[0027] Such a first groove preserves the structural intactness of the
anode block and therefore its physical resistance owing to the fact that
the essential part of the first groove is formed in the heart of the
material. The outer envelope, which has a greater propensity to undergo
strain and to be split than the heart of material, is then weakened to a
lesser extent with such a first groove which has less surface leading
onto the outer faces of the anode block as compared to a groove known
from prior art.

[0028] The groove leads onto a single lateral side or two opposite lateral
sides of the anode block to facilitate removal of the gas building up
under the anode block.

[0029] According to a particular embodiment of the invention, the groove
may have a bottom that is slightly tilted by an angle of less than
10° in relation to the horizontal, to improve gas removal and to
direct this removed gas to a predetermined place in the cell, for example
to the points where alumina is loaded so as to facilitate stirring and
dissolution of the alumina, and more particularly towards a central
corridor in the electrolysis cell.

[0030] The special and innovative shape of the first groove according to
the invention endows it with a period of full efficiency that is out of
step with the grooves of prior art formed from the lower face. As the
first groove does not lead onto the lower face or leads onto the lower
face over a short length, it is ineffective, or of limited effectiveness,
for gas removal in the first moments that the anode block is immersed in
the electrolysis cell. The first groove becomes fully effective after a
certain amount of wear of the anode block, when the length of groove
leading onto the lower face increases.

[0031] The association of at least one first groove with at least one
second groove from prior art in an anode block for anode is therefore
particularly advantageous. "Second groove" is taken to mean a groove of
maximum length L'max in a plane parallel with the lower face and
leading onto the lower face over a length L'0 equal or substantially
equal to L'max, for example when the lower edge of the anode block
is chamfered.

[0032] So when a new anode is fitted in an electrolysis cell, the second
groove allows the removal of gas building up under the anode and when the
second groove disappears as a result of wear of the anode block, the
first groove takes over for the removal of gas building up under the
anode. The periods of effectiveness of the first and second grooves may
overlap, i.e. the first and second grooves may coexist at the same depth
in relation to the lower face, or they may be slightly separate.

[0033] The anode block may include one or more first grooves and one or
more second grooves. The direction of the various grooves may vary; the
first grooves may, for example, be perpendicular to the second grooves.

[0034] So as compared to an anode block from prior art, for which carbon
consumption or wear caused the move from an effective groove to no
groove, with the anode blocks according to the invention comprising at
least one first groove and at least one second groove, there is a move
from a second groove to a first groove, which avoids disturbances and
abrupt changes in fluid kinetics with the related problems of electrical
equilibrium, and facilitates, for example, adaptive adjustments.

[0035] According to an example of a particularly advantageous embodiment
of the invention, the anode block comprises two second grooves and one
first groove, the first and the second grooves extending in parallel in
the longitudinal direction from the anode block and the first groove
being laid out halfway between the two second grooves. Offsetting the
first groove in a plane parallel with the lower face, in relation to the
two second grooves therefore allows optimal conservation of the physical
intactness of the anode block.

[0036] According to an advantageous embodiment, length Lo over which
the first groove leads onto the lower face is less than 25% of the
maximum length Lmax and preferably less than 10% the maximum length
Lmax. The lower the length L0 over which the first groove leads
onto the lower face, the greater the physical intactness of the anode
block. So a preferred example of an embodiment will correspond to the
case in which the groove does not lead onto the lower face. The fact that
the first groove leads onto the lower face results mainly from a
manufacturing process that is particularly advantageous because it is
simple to implement, in which: [0037] a blade is inserted inside a
vibrocompactor mold; [0038] the vibrocompactor mold is loaded with
carbonaceous materials that make up the anode block; [0039] the
carbonaceous materials are vibrocompacted; and [0040] the anode block
formed in this way is removed from the mold, in particular by slippage in
relation to the blade.

[0041] According to another embodiment, the anode block is removed from
the mold after withdrawing the blade from the mold.

[0042] According to an advantageous embodiment of the invention, the blade
is fixed to the bottom of the mold before loading.

[0043] According to another advantageous embodiment of the invention, the
blade is fixed to one lateral face or two opposed lateral faces of the
mold before loading

[0044] The invention extends to anodes with at least one anode block as
described above and a fixing rod.

[0045] The invention also extends to a cell for the production of aluminum
by igneous electrolysis comprising at least one anode as described above,
and to a process for the manufacture of aluminum including the stages
consisting of: [0046] providing at least one anode as defined above;
[0047] fitting the anode in an aluminum electrolysis cell; [0048] sending
current into the electrolysis cell through the anode; [0049] recovering
the aluminum obtained by electrolysis in the bottom of the electrolysis
cell.

[0050] The invention is described in greater detail below using the
annexed figures.

BRIEF DESCRIPTION OF THE FIGURES

[0051] FIG. 1 is a cross-sectional view of a typical electrolysis cell for
the production of aluminum.

[0052] FIGS. 2A and 2B give a front view of an embodiment of an anode
block according to the invention.

[0053] FIG. 3 shows a cross-section of the anode block in FIGS. 2A and 2B
along section A-A to highlight the shape of the first groove.

[0054] FIG. 4 is a front view of a blade designed to be fixed into a mold
to form the first groove during the manufacture of the crude anode block
in FIGS. 2 and 3.

[0055] FIGS. 5 to 7 are cross-sections like those in FIG. 3, showing other
special shapes for first grooves.

[0056] FIGS. 8A and 8B respectively give a front view of another
embodiment of an anode block according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0057] Electrolysis plants for the production of aluminum include a liquid
aluminum production area containing one or more electrolysis halls
containing electrolysis cells. The electrolysis cells are normally laid
out in lines or files, each line or file comprising typically more than a
hundred cells, and electrically connected in series using connection
conductors.

[0058] As illustrated on FIG. 1, an electrolysis cell 1 includes a cell 2,
a support structure 3, called "superstructure", carrying a plurality of
anodes 4, means 5 to supply the cell with alumina and/with AlF3 and
means 12 to recover the effluents emitted by the cell when in operation.
Cell 2 typically includes a steel pot shell 6 lined internally with
refractory materials 7, 8, a cathode unit which includes blocks made of
carbonaceous material 9, called "cathode blocks" laid out in the bottom
of the cell, and metal connection bars 10 to which electric conductors 11
are fixed used to supply the electrolysis current. Anodes 4 each comprise
at least one consumable anode block 13 made of pre-baked carbonaceous
material and a metal rod 14. The anode blocks 13 have are typically
substantially parallelepipedic in shape. The rods 14 are typically fixed
to the anode blocks 13 via fasteners 15, generally called "multipodes",
comprising pins which are anchored in the anode blocks 13, generally via
recesses 36 in the upper face of the anode block. Anodes 4 are fixed so
as to be removable onto a mobile metal framework 16, called an "anode
frame", by mechanical means of fixing. The anode frame 16 is supported by
superstructure 3 and is fixed to electric conductors (not illustrated)
used to supply the electrolysis current.

[0059] The refractory materials 7, 8 and the cathode blocks 9 form, inside
cell 2, a crucible able to contain an electrolyte bath 17 and a layer of
molten metal 18 when cell 1 is in operation. In general, a blanket 19 of
alumina and solidified bath covers the electrolyte bath 17 and all or
part of the anode blocks 13.

[0060] Anodes 4, and specifically the anode blocks 13, are partially
immersed in the electrolyte bath 17, which contains dissolved alumina.
The anode blocks 13 initially each have a typically mainly plane lower
face, parallel to the upper surface of the cathode blocks 9, which is
generally horizontal. The distance between the lower face of the anode
blocks 13 and the upper surface of the cathode blocks 9, known as the
"interpolar distance", is an important parameter for regulating the
electrolysis cells 1. The interpolar distance is generally controlled
with a high degree of accuracy.

[0061] The carbonaceous anode blocks are gradually consumed during use. In
order to compensate for this wear, it is current practice to gradually
lower the anodes by moving the anode framework regularly downwards. In
addition, as illustrated in FIG. 1, the anode blocks are generally at
different stages of wear, advantageously to avoid having to change all
the anodes at the same time.

[0062] FIGS. 2A, 2B and 3 show a first embodiment of an anode block 13a
according to the invention. The anode block 13a is typically of
right-angled parallelepipedic shape of length L between two opposite
short side faces 21 and 22 typically vertical and of height H between a
typically horizontal lower face 23 and a higher face 24. As shown in
FIGS. 2A, 2B and 3, the higher edges can be cut away to limit carbon
losses. The anode blocks are designed to be consumed down to a maximum
wear height indicated by arrows 25.

[0063] The anode block 13a comprises a first groove 31a and two second
grooves 32 and 33.

[0064] The second grooves 32, 33 typically pass right through the anode
block in the direction of length L. FIGS. 2A and 2B, which shows the
short opposite side faces 21, 22 of the anode block 13a, show that these
second grooves 32, 33 lead onto the lower face 23 throughout its length
and onto the two short side faces. Consequently, the second grooves 32,
33 lead onto the lower face 23 over lengths L'0 equal to their
respective maximum lengths L'max and also equal to L. In cases where
the lower edges are cut away, these lengths L'max, and L'0 are
also substantially equal owing to the fact that the cut away part is not
significant.

[0065] To make the figures easier to understand, the scales are not
strictly respected in the figures, in particular with regard to the width
of the grooves, the width of the grooves typically ranging between 5 and
40 mm while the width of the anode blocks, corresponding to the short
side faces generally ranges between 550 and 700 mm. In FIGS. 2A, 2B (and
also in FIGS. 8A and 8B) dotted lines are used to show the non visible
parts of the faces that are seen by transparency. FIG. 3 is a view of the
anode along section A-A through the first groove 31 in order to show more
specifically the shaped of the first groove 31.

[0066] The first groove 31 a comprises over its length:

[0067] a first portion I forming a perforation or a recess in the heart of
the carbonaceous material and not leading onto the lower face 23 of the
anode block 13a;

[0068] a second portion II leading to the lower face 23 of the anode block
13a.

[0069] So when the anode block 13a is whole, the first groove 31a, shaped
like an L lying on its side and includes, on the first portion I, a
bottom 40 and a lower wall 42 and only the bottom 40 on the second
portion II.

[0070] The first groove 31a leads onto the two short side faces 21, 22 of
anode block 13a for removal of the gas building up under the anode. The
maximum length Lmax of the first groove 31a in a plane parallel to
the lower face is therefore equal to the length L of the anode. The first
groove 31a, in contrast, leads onto the lower face 23 over a length
Lo that is short in relation to the maximum length. To preserve
physical intactness and sufficient resistance for the anode block while
maintaining significant gas drainage properties, the applicant considers
that Lo must be less than half of Lmax and preferably less than
25% of Lmax and preferably still less than 10% of Lmax.

[0071] The first groove 31a extends in parallel and halfway between second
grooves 32, 33 so as to preserve the physical intactness and resistance
of the anode block 13a as much as possible.

[0072] As can be seen in FIGS. 2A and 2B, the second grooves 32, 33 have a
bottom 44 laid out at the same height in the anode block 13a as the lower
wall 42 of the first groove 31a. So when the second grooves 32, 33 are
worn and disappear, the first portion I of the first groove takes over,
allowing gases to be removed.

[0073] The anode block 13a and the anode formed from this anode block 13a
allow effective continuous removal of gases formed in the electrolysis
cell.

[0074] Dotted lines in FIG. 2A, 2B show recesses 51 forming sites inside
which the pins of the "multipodes" can fit. In this example, the anode
block 13a specifically shows six cavities 36 laid out in two lines. These
recesses are moreover very shallow and consequently have little impact on
the intactness of the anode block structure.

[0075] The existence of the second portion II of the first groove 31a,
which leads onto the lower face of the anode designed to be laid out
opposite a higher face of a cathode laid out in the bottom of the
electrolysis cell is dictated by an adapted version of the conventional
method for manufacturing anode blocks. As this second portion II is a
source of anode block embrittlement, it is attempted to decrease its
length and therefore its impact so that the invention is limited to anode
blocks in which the length Lo is less than half of Lmax, and
preferably less than 25% of Lmax and preferably still less than 10%
of Lmax.

[0076] A conventional way of manufacturing a grooved anode block involves
introducing the material that makes up the anode block into a mold of
globally parallelepipedic shaped and comprising one or more blades fixed
into the bottom of the mold to form the grooves by complementarity. The
material of the anode block is then packed by pressurizing or
vibrocompacting, the side faces of the mold raised and the anode block
pushed beyond the bottom of the mold. During pushing, the anode block is
more particularly made to slip in relation to the blades. According to a
variant, the blade is withdrawn before pushing.

[0077] FIG. 4 shows a blade 46 used to obtain in a vibrocompactor a first
groove 31a according to the invention. This blade 46 comprises more
specifically a means 48 for fixing the blade into the bottom of the mold.
This means 48 for fixing is more specifically made up of screws. The
portion of the blade used for this fixing corresponds more specifically
to the second portion II of the first groove 31a.

[0078] As can be seen in FIG. 4, blade 46 may additionally comprise, for
example, a notch 50 complementary to a reversible means of fixing
provided in a side face of the mould. Although optional, this fixing at
an end opposite to means 48 for fixing blade 46 in the bottom of the mold
allows the blade to be held properly in the mold, especially with regard
to vertical and/or lateral movement. Maintaining the blade this way
allows an improvement of the quality of the anode production,
particularly a reduction of the cracking rate of the anodes during the
cooking, and an increase of the life-time of the blade that is less
subject to flex. When removing the anode block 13a from the mold, the
reversible means of fixing of notch 50 is disengaged, the side faces of
the mold are raised and the anode block is slid in relation to blade 46.

[0079] Additionally, the blade can advantageously be fixed with regard to
a lateral face of the mold at the end of the blade proximal to the means
48 for fixing blade 46. The use of such second reversible means for
fixing, that can for example be constituted by a groove provided in the
lateral face of the mold and in which the end of the blade slide and stay
in place, limits also the move, deformation and wear of the blade.

[0080] According to a variant of the manufacturing process, blade 46 can
be raised in a removable way in the mold so that blade 46 can be
withdrawn from anode block 13a before anode block 13a is pushed out of
the mold.

[0081] FIG. 5 shows another anode block 13b with a first groove 31b
comprising a bottom 40 tilted in relation to the horizontal so as to
improve the speed of gas removal and to encourage gas to be removed to a
particular point in the electrolysis cell. The slope of bottom 40 in
relation to the horizontal more specifically ranges between 1 and
10°.

[0082] In FIG. 6 another anode block 13c is shown, with a first groove 31c
having a maximum length Lmax in a plane parallel to the lower face
shorter than length L of anode block 13c and leading onto a single side
face 22 of anode block 13c. Length Lo of the first groove 31c
leading onto the lower face 23 is less than half of Lmax to preserve
the physical intactness and the resistance of the anode block while
maintaining significant gas drainage properties.

[0083] FIG. 7 shows another anode block 13d with a first groove 31d
extending through the material of anode block 13d between the two
opposite short side faces 21, 22 without leading onto the lower face 23
of anode block 31d. Such a first groove 31d is particularly advantageous
because it does not influence the integrity of the anode block at the
level of the lower face 23. The blade inserted into the vibrocompactor
mold for molding the anode block is then attached to the side faces of
the mold and not to the bottom of the mold. The opposed lateral faces of
the mold can for example be provided with two holes in the shape of slots
through which the blade is slid, maintained in suspension and fixed by
means of locking devices. A placing and retracting cylinder associated to
a gripping means of the blade can be used to put the blade in place in
the mold before the loading of the carbonaceous materials that make up
the anode block and to retract the blade of the raw compacted anode block
and of the mold before unloading of the mold.

[0084] The invention also extends to an anode block comprising only one or
more first grooves, without second grooves. The structural intactness of
the anode block will then be similar to an anode block without grooves
and improved gas removal will be obtained during the period when the
first groove(s) will lead onto the lower face over a significant length.

[0085] The invention is not limited to embodiments described above but
extends to all the embodiments readily available to experts in the field
in the light of the information given above.

[0086] The bottom of the second grooves and the lower wall of the first
groove can, for example, be provided at slightly different heights so
that the first and second grooves coexist for a certain amount of time
or, on the contrary, so that there is a period of time without any
effective groove after the second groove has worn down and the first
groove effectively appears. The number of first and or second grooves may
vary, as may their respective positioning and/or respective orientation.

[0087] Another anode block 13e is therefore shown in FIGS. 8A and 8B as a
front view along the short side face 21 and a long side face 34
respectively. The anode block 13e comprises two second grooves 32, 33
extending longitudinally and four first grooves 31e extending laterally
and not leading onto the lower face 23. The first grooves 31e therefore
extend transversely to the second grooves 32, 33. The bottom 44 of the
second grooves is advantageously laid out below the lower wall 42 of the
first grooves 31e, which prevents weakening the resistance of anode block
13e by intersections of the various grooves.

[0088] Depending on variants of the invention, a second groove can be
taken to mean any groove of a type known from prior art, leading onto the
lower face over a length equal or substantially equal to their maximum
length. The second grooves may in particular be of the type known from
the documents of patent WO 2006/137739 or U.S. Pat. No. 7,179,353.